SERVICE MANUAL R1100 GENERATORS. Models. PUB-GS2363 Rev. 04/07

Transcription

1 SERVICE MANUAL Models R1100 GENERATORS PUB-GS2363 Rev. 04/07

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3 CONTENTS Section Title Page 1. SPECIFICATIONS SPECIFICATIONS PERFOMANCE CURVES GENERAL DESCRIPTION EXTERNAL VIEW CONTROL PANEL LOCATION OF SERIAL NUMBER AND SPECIFICATION NUMBER ALTERNATOR RANGE OF APPLICATIONS MEASURING AND CHECKING PROCEDURES INSTRUMENTS AC OUTPUT MEASURING MEASURING INSULATION RESISTANCE CHECKING FUNCTIONAL MEMBERS ASSEMBLY AND DISASSEMBLY PRECAUTIONS SPECIAL TOOLS DISASSEMBLY PROCEDURES REASSEMBLE PROCEDURES RECOIL STARTER TROUBLESHOOTING WIRING DIAGRAM The specifications and information included in this manual were in effect at the time of printing. FUJI HEAVY INDUSTRIES LTD. reserve the right to change the specifications and to make modifications in the course of technical progress, at anytime without notice. No parts of this manual may be reproduced without written permission.

4 1. SPECIFICATIONS 1-1) SPECIFICATIONS Engine Alternator Equipment Type Frequency Model Type Starting system MODEL Alternating electric current (AC) Maximum output Rated output Output Displacement Fuel Fuel tank capacity (at Rated output) Oil pan capacity Spark plug Hz VA VA W ml(cc) L hours Alternating electric current output Direct Current Output Dimension Length x Width x High Dry weight kg Rated voltage Direct Current (DC) Rated continuous operation [Approx.] Ignition System Over current protector Alternating electric current (AC) output Direct Current (DC) output Oil Sensor Output Lamp Oil Warning Lamp L mm kg Specifications are subject to change without notice. V Rated current A Rated power factor 1.0 Voltage V 12 Power Current A Receptacle (15A x 2) Forced air-cooled, 4-cycle, OHV Gasoline Engine 3.8 R Pole, Revolving Field type Self Exciting, Single Phase AVR type Automotive Unleaded Gasoline Solid-state flywheel magneto NGK BMR4A Recoil starter Receptacle (15A x 2) Terminal Current breaker Current breaker STD STD STD 480 x 295 x EH09-2D Receptacle (20A x 2) 1

5 1-2) PERFOMANCE CURVES 50Hz - 230V FREQUENCY (Hz) OUTPUT VOLTAGE (V) OUTPUT POWER (VA) OUTPUT CURRENT (A) 50Hz - 240V FREQUENCY (Hz) OUTPUT VOLTAGE (V) OUTPUT POWER (VA) OUTPUT CURRENT (A) 4.0 2

6 60Hz - 120V FREQUENCY (Hz) OUTPUT VOLTAGE (V) OUTPUT POWER (VA) OUTPUT CURRENT (A) 3

7 2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW RECOIL STARTER (HANDLE) CONTROL PANEL AIR CLEANER FUEL DRAIN SCREW SIDE PANEL (L) CARRYING HANDLE TANK CAP COVER SPARK PLUG CAP OIL GAUGE (OIL FILLER) EXHAUST OUTLET SIDE PANEL (R) OIL DRAIN PLUG 4

8 2-2) CONTROL PANEL PILOT LAMP OIL SENSOR LAMP AC RECEPTACLES AC CIRCUIT BREAKER DC TERMINALS ENGINE SWITCH DC CIRCUIT BREAKER GROUND TERMINAL (1) ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished. STOP ENGINE SWITCH RUN (CHOKE) " " (RUN) To start the engine, turn the knob to the position. (Choke valve is closed.) Keep the knob in this position after the engine starts. (The engine can be started with the knob at this position when the engine is warm.) CHOKE " " (STOP) To stop the engine, return the knob to the position. (The fuel cock is closed as well.) 5

9 (2) OUTPUT LAMP Green light Indicates that the generator is generating. Unlit The generator is not generating. OUT PUT (3) OIL SENSOR LAMP When the level of the engine oil falls below the prescribed value, the alarm lamp lights up and the engine stops automatically. When the engine stops due to oil shortage, it can not be started anymore even by pulling the start knob (just the alarm lamp flickers). In such a case, replenish engine oil up to the mouth of the oil filling port. (4) AC RECEPTACLES AC electric power is available through this receptacle. Use a ground type, three-leg plug. 6

10 (5) DC TERMINALS DC electric power for battery charge is available. - Red is positive (+) terminal. - Black is negative (-) terminal. (-) DC TERMINAL (+) DC 12V 8.3A (6) DC CIRCUIT BREAKER DC circuit breakers shut off electric current when the current exceeds its limit. Check for excessive current consumption. After making sure everything is in order, push the button to the " ON " position. Fully dischanged battery of large capacity may cause over-current in DC output circuit. BUTTON KNOB IN (ON) OUT (OFF) (7) AC CIRCUIT BREAKER AC circuit breaker will cut off electric current when the current exceeds its limit or a malfunction occurs in the connected appliances. Check for excessive current consumption or defects in the appliances. After making sure everything is in order, push the circuit breaker button. BUTTON KNOB IN (ON) OUT (OFF) 7

11 2-3) LOCATION OF SERIAL NUMBER (SER No.) PRODUCTION NUMBER (PROD No.) The serial number and production number are located on right side cover of the generator operation panel. Serial number and Production number (Label) NOTE : Please specify these numbers when inquiring about the generator or ordering spare parts. 2-4) ALTERNATOR Diode Rotor CP Rear cover Brush holder Ball bearing Stator CP Through bolt AVR unit Rotor shaft Flywheel 8

12 3. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption (input wattage). The power consumption of an electrical appliance is the power necessary for using it. When using a generator for operating an electrical appliance, the power factor and starting wattage must be taken into consideration. In order to determine the right size generator, it is necessary to add the total wattage of all appliances to be connected to the unit. Refer to the followings to calculate the power consumption of each appliance or equipment by its type. (1) Incandescent lamp, heater, etc. with a power factor of 1.0 Total power consumption must be equal to or less than the rated output of the generator. Example : A rated 3000W generator can turn thirty 100W incandescent lamps on. (2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3 times lager than their running wattage. Example : A rated 250 W electric drill requires a 400 W generator to start it. NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power shall be required to drive the lamps. NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp. Therefore, if the fluorescent lamp has no special indication as to the power consumption, efficiency should be taken into account as explained in ltem (5) on the following page. (3) Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up. Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated 3000 W generator can power two or three 400 W mercury lamps. (4) Initially loaded motor driven appliances such as water pumps, compressors, etc. These appliances require large starting wattage which is 3 to 5 times of running wattage. Example : A rated 900 W compressor requires a 4500 W generator to drive it. NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting. Once their motors are started, the appliances consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances. NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity. 9

13 (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below. (Output of electrical appliance) = (Power consumption) (Efficiency) Efficiencies of some electrical appliances are as follows : Single-phase motor to 0.75 (The smaller the motor, the lower the efficiency) Fluorescent lamp to 0.8 Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and accordingly, power consumption will be = 57W. As explained in Item (2), multiply this power consumption value of 57W by 1.2 to 2 and you will get the figure of the necessary capacity of a generator. In other words, a generator with a rated output of 1000W capacity can light nine to fourteen 40W fluorescent lamps. Example 2 : Generally speaking, a 400W motor means that its work load is 400W. Efficiency of this motor is 0.7 and power consumption will be = 570W. When this motor is used for a motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W as explained in the ltem (3). The power consumption of electrical appliances is shown below for reference, use this as a measuring guide when choosing electrical appliances and which generator to use. Electrical Appliances Electrical Appliances Electrical appliances Starting wattage Electrical appliances Power Consumption (W) Electrical appliances Starting wattage Electrical appliances Power Consumption (W) Household Appliances One of power consumption 1.2 to 2 times of power consumption 3 to 5 times of power consumption Rice Cooker Coffee Maker Electric grill Color TV Hair dryer Air conditioner Microwave Lawn mower Refrigerator Vacuum cleaner Washer Air Cooler Deep well pump 300 to to to to Electrical tools /Architecture One of power consumption 1.2 to 2 times of power consumption 3 to 5 times of power consumption Soldering iron Lighting for young sardines Drill Disc Grinder Electrical hammer Chain sow Impact wrench Vibrator Drill for shiitake Air compressor Winch water pump 300 to to to to to Mercury lamp 40 to

14 NOTES : Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out. The table below shows cables and their allowable currents for your reference. 2. Cable length If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors decreasing the input voltage to the load (electrical product). As a result, the load can be damaged. The table below shows voltage drops per 30 meters of cable. Cross sectional mm 2 Allowable Current A Cable Resistance /100m 5A Voltage drops per 30 meters of cable 10A 15A 20A 25A 30A V 8.9V V 5.7V 8.6V V 3.1V 4.7V 6.2V V 2.0V 3.0V 4.0V 5.0V 6.0V Voltage drop indicates as V= x R x I x L R : Resistance ( /100m) I : Electric current (A) L : Length (m) The length of wire (L) indicates round length, which is the length from the generator to the electrical tools and back. <Example> R : Resistance 1.25mm 2 =1.48 /100m I : Electric current 10A L : Length 30m The voltage drop of the case described above V= 1.48 x 10A x (30m x 2) 8.9 (V)

15 4. MEASURING AND CHECKING PROCEDURES 4-1) INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows : 0 to 150 V : Type with an output voltage of 110 or 120 V 0 to 300 V : Type with an output voltage of 220, 230 or 240 V 0 to 150 V, 0 to 330 V : Dual voltage type For AC For DC (2) AMMETER AC ammeter is necessary. An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable. (About 10 A, 20 A, 100 A) For AC For DC (3) FREQUENCY METER Frequency range : To cover 45 to 65Hz NOTE : Be careful of the frequency meter's input voltage range. 12

16 (4) CIRCUIT TESTER For measuring resistance, etc. NOTE : The ordinary circuit tester may cause erroneous readings due to their measuring method. Use a high-grade, precise circuit tester to check the generator components. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V. (6) TACHOMETER Use the contactless type tacho meter for checking engine speed. 13

17 (7) "Dr.Robin" GENERATOR TESTER The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The "Dr.Robin" has the following features : 1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit. 2) Fast and easy readout by digital indicator. 3) Built-in automatic battery checker indicates the time to change batteries. 4) Tester and accessories are installed in a handy, sturdy case for easy carrying. SPECIFICATIONS MODEL Dr.Robin Part Number Measuring Range Circuit Protector Power Source Accessories Dimensions (L x W x H) Weight Voltage Frequency Resistance Condenser Capacity Insulation Resistance 0 to 500 V AC 25 to 70 Hz 0.1 to 1,999 Ω 10 to 100 F 3MΩ Fuse 2 x 6F44P (006P) Dry Cell Battery Test leads with needle probes... 1 set Test leads with jack plugs... 1 set 285 mm x 200 mm x 110 mm 1.6 kg The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number. Dr.Robin_Part_Number_:_ If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for checking generator parts. 14

18 4-2) AC OUTPUT MEASURING SWITCH LOAD A ~ TO AC RECEPTACLE F V ~ Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm, and check that the voltage range is as specified in the following table at the rated amperage and rated rpm. Rated voltage 60Hz-120V 50Hz-230V 50Hz-240V Voltage range ) MEASURING INSULATION RESISTANCE (1) Connect the megger tester across either one of the two output terminals of the AC receptacle and ground terminal to measure the insulation resistance. Measure it with the AC breaker on. An insulation resistance of 1 M or more is normal. Original insulation resistance at the time of shipment from the factory is 10 M or more. If it is less than 1 M, disassemble the generator and measure the insulation resistance of the stator, rotor and control panel individually. 15

19 (2) ALTERNATOR Measure insulation resistance between each terminal (Black or White) of 6-P connector from the stator and the stator core. If there is a wire which has insulation resistance less than 1 M, replace the stator. Insulation failure cause electrical leak which may result in electrocution. (3) CONTROL PANEL With AC breaker turned ON, measure insulation resistance between each portion of electrical parts and earth (grounding) terminal or control panel itself. Measure with the AC breaker on. If there is a spot where insulation resistance less than 1 M, replace the part. Insulation failure may result in electrification, or an electrical leak. 16

20 4-4) CHECKING FUNCTIONAL MEMBERS (1)STATOR Measure the winding wire resistance. Check the resistance of the wires that comes out from the stator using a tester, referring to the following table. NOTE: When measuring according the numerical value shown in the chart, tolerance should be considered because the inaccuracy of the tester. If an accurate value is needed, measure by electric resistance using an Ohm-meter. While doing this, use caution to avoid contact resistance. Generator wire resistance Color of the wires AC 120V Specification AC 230V Specification Unit ; AC 240V Specification Main coil Black-White Exciter coil Yellow-Yellow DC coil Brown-Brown (2) ROTOR ASSEMBLY 1) Field coil Measure resistance between the slip rings. Rotor Slip ring Resistance ( ) Field coil (Between two Slip rings) 35 NOTE : When measuring, tolerance should be considered because of the tester inaccuracy, winding number variation, ambient temperature etc. 2) Cleaning Slip rings The slip ring surfaces must be uniformly bright. Slip rings showing black spots, excessive wear, or uneven wear must be repaired. A stained slip ring lowers generator efficiency and output voltage. Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear. NOTE : Care should be taken not to touch the rotor coils with the sandpaper. Slip ring Sandpaper Rotor 17

21 3 BRUSH The brushes must be smooth where they contact the slip rings. If not, polish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip ring lowers generator efficiency and output voltage. Brush holder 5 mm Brush 4 AC CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the AC circuit breaker while it is mounted on the control panel. (5) DC CIRCUIT BREAKER Check that there is continuity between the two terminals of DC circuit breaker when its push button is pressed. Circuit breaker No continuity Continuity 18

22 (6) A.V.R (AUTOMATIC VOLTAGE REGULATOR) 1) Features This AVR operates to control the field current in order to maintain the output voltage for the AC current, which generated by the magnetic flux by the field coil. 2) A.V.R. trouble may be identified by simply looking at the A.V.R., or by the inter-lead resistance with a tester, or actually mounting it in the generator and operating it. a b P Connector (a) A.V.R. TROUBLE IDENTIFICATION by APPEARANCE If an A.V.R. electronic part is burnt dark, or the surface epoxy resin melted, it often indicates A.V.R. trouble. (b) IDENTIFYING A.V.R. TROUBLE by CHECKING INTER-LEAD RESISTANCE Check the inter-lead resistance of the A.V.R. with a tester, referring to the following table. If the tester readings very greatly from the values specified in the table, the A.V.R. is faulty. Apply black needle of the circuit tester a Orange b Orange/Green a Orange b Orange/Green No continuity Apply red needle of the circuit tester No continuity 4 (c) IDENTIFYING A.V.R. TROUBLE by MOUNTING and OPERATING in THE GENERATOR SCR or transistor damage cannot be detected by simply looking at the A.V.R. or checking the lead resistance. Check it by mounting the suspectedly faulty A.V.R. in a normal generator, or mount a normal A.V.R. in a generator which fails to generate voltage. 19

23 (7) DIODE RECTIFIER The internal circuit of the diode rectifier is shown in the figure below. Check the continuity between each terminal using a circuit tester. If the continuity is as charted below, the diode rectifier is normal Checking table for analogue circuit tester Analogue circuit tester Apply black needle of the circuit tester No continuity Continuity Apply red needle of the circuit tester No continuity Continuity No continuity No continuity Checking table for degital circuit tester Degital circuit tester (Dr.Makita) Apply red needle of the circuit tester No continuity Continuity Apply black needle of the circuit tester No continuity Continuity No continuity No continuity (8) RECEPTACLE, AC PLUG Check burn marks in the areas where electric current flows, such as wire and plastic parts of AC receptacle. 20

24 (9) OIL SENSOR Confirm that there is a sufficient amount of oil.measure continuity between the wires of oil sensor and the crankcase using a circuit tester. Oil Sensor Below the lower level : ON (continuity) Above the lower level : OFF(non-continuity) 0 Use 4-stroke automotive detergent oil of API service class SE or higher Grade (SG, SH or SJ is recommended). Oil capacity : 0.4 liters 21

25 5. ASSEMBLY AND DISASSEMBLY 5-1) PRECAUTIONS (1) Be sure to memorize the location of each part when disassembling the generator so that the generator can be correctly reassembled. Tag the disassembled parts with the necessary information to facilitate easier and smoother reassembling. (2) For greater convenience, divide the parts into several groups and store them in boxes. (3) To prevent bolts and nuts from being misplaced or installed incorrectly, place them temporarily back at their original position. (4) Handle disassembled parts with care; wash them with clean oil. (Do not clean electrical parts with oil nor water.) (5) Use proper tools correctly for each specific job. (6) Please be sure to glue the sponge inside the cover. Please replace the sponge if it is deformed, peeled, or damaged, with a new one. The generator performance may be negatively affected by the lack of a sponge or deformed, peeled or damaged sponge. (7) Tie the electric wires and fuel pipe with wire bands as necessary. Please refer to Robin Engine Service Manual EH09 for the assembly and disassembly of the engine. 5-2) SPECIAL TOOLS Use the proper, specialized tools for disassembly and assembly. By using the proper, specialized tools, maintenance trouble and damage of the equipment can be avoided. Parts No. Name of the tool Form Use method 33K Rotor puller To remove Flywheel with Rotor 22

26 5-3) DISASSEMBLY PROCEDURES Please disassemble in the order of the procedure below Remove the side panels (Left, Right) Remove the side panels. M6 16.5mm Bolt 2 pcs. Tools : Screw driver Side Panel Remove the rear cover Remove the rear cover by unscrewing the four screws. M6 20mm Screw and Washer 4pcs. Tools : Screw driver Rear cover Remove rolling wire, choke wire Remove chock lever swivel screw fixing chock wire. Untighten adjusting screw nut, remove adjust screw from chock wire bracket, and then take out choke wire from swivel. Unwind the rolling wire by hand or pliers, and pull up. Wire Nut Choke wire Adjusting screw Choke wire Choke wire bracket Tools : Screw driver, pliers Rolling wire 23

27 5-3-4 Remove the recoil starter handle Remove the recoil starter guide connected to the case body (left). Push the guide and the starter hundle through the hole which the case body (left) guide was attached. M4 x 10mm Tapping screw 1pce. Tools : Screw driver Recoil starter hundle Guide Overflow pipe Remove the control panel (1) Remove the control panel from the case body. M4 x 14mm Screw 4pcs. M5 x 8mm Screw 4pcs. Tools : Screw driver Case body Control Panel NOTE: At this point, the couplers of electrical wires are connected to the control panel. Instead of removing the control panel forcibly, remove it after disassembling the case body and fuel tank Remove the case body (Left, Right) Remove the case body (Left, Right) Remove the plastic pipe from the case body. (Overflow pipe) Upper part of the case body M6 x 25mm Screw and Washer : 2pcs. M6 x 20mm Screw and Washer : 1pce. M4 x 110mm Screw : 1pce. Tools : Screw driver Bottom part of the case body Remove the case with the mount still fastened to it. M6 x 18mm Flange bolt : 4pcs. Tools : 10mm Box wrench Case body Mount 24

28 5-3-7 Remove rear frame Remove the rear frame. Front frame Rear frame Remove fuel cock bracket Remove the fuel cock bracket. Fuel pump M6 x 12mm Flange bolt 1pce. M6 Nut 1pce. Tools : 10mm Box wrench NOTE 1: Be sure to close the fuel cock before removing the fuel pipe. (Engine switch in the off position) NOTE 2: A little fuel comes out from the fuel pump when unplug the pipe. Unplug the pipe Fuel cock bracket Remove the fuel tank Remove the fuel tank with the fuel cock still connected. Fuel tank 25

29 Remove the control panel (2) Remove the control panel by pulling off the three couplers. Remove the choke wire bracket from the front frame. Couplers Disconnect AVR coupler and Diode coupler. Couplers (Diode) Couplers (AVR) Remove the fuel pipes Remove the fuel pipe from the fuel pump to carburetor and the fuel pipe on crank case side. Fuel pipe (Carburetor side) Tools : Pliers Fuel pipe (Crank case side) 26

30 Remove the air cleaner and carburetor Unhook the catch on the right side of the air cleaner. Then remove the air cleaner cover and elements. Air Cleaner Loosen the two nuts and bolt to remove the base plate of the air cleaner. Carburetor Then remove the carburetor. M6 x 18mm Flange bolt : 1pce. M6 Flange nut 2pcs. Tools :10mm Box wrench Base plate Grounding wire Remove the grounding wire. Tools : Screw driver Grounding wire Remove the front frame Remove the front frame. Front frame 27

31 Remove the Base Remove the Base. M6 nut : 4 pcs, also M8 x 16 Bolt and washer : 4pcs. Tools : 12mm Box wrench Base Remove the Brush holder Remove the Brush holder. Brush holder M5 x 14mm Screw 1pce. Tools : Screw driver 28

32 Remove the Stator / Rear cover Remove the Stator / Rear cover. Rear cover M6 x 25mm Flange bolt : 3pcs. Tools : 10mm Box wrench NOTE : The stator is attached to the rear cover, both can be removed together. Rear cover Stator Remove the rotor and Flywheel Remove the rotor and Flywheel. M8 x 195mm Rotor bolt : 1pce. Tools : 12mm Box wrench NOTE 1: Flywheel can be removed with Rotor at the same time. NOTE 2: Counterclockwise threads are applied onto the Rotor (through) bolt. Take care when removing. Rotor Bolt Rotor Remove Blower housing Remove the blower housing. M8 x 55mm Flange bolt : 1pce. M8 x 90mm Flange bolt : 3pcs. Blower Housing Tools : 12mm Box wrench NOTE : The pipe knock is attached to two places. 29

33 Remove recoil starter Remove the recoil starter. M6 x 20mm AY Bolt : 3pcs. Tools : 10mm Box wrench NOTE: For the maintenance of recoil starter, please refer to item "5-5) Disassembly and assembly of the recoil starter". Recoil starter Remove the muffler Remove the muffler. M8 x 80mm Flange bolt : 1pce. M6 Flange nut : 2pcs. Tools : 10mm Box wrench 12mm Box wrench Muffler Remove the ignition coil Remove the ignition coil. Ignition coil M6 x 14mm Flange bolt : 2pcs. Tools : 10mm Box wrench 30

34 Remove the cylinder baffle Remove the cylinder baffle. Cylinder baffle M8 x 16mm Flange bolt : 3pcs. M6 x 12mm Flange bolt : 1pce. Tools : 10mm Box wrench 12mm Box wrench By performing the above steps, only a bare engine remains. Please refer to EH09 Service manual for further disassembly and service procedures of the engine. 31

35 5-4) REASSEMBLY PROCEDURES Cylinder baffle Install the cylinder baffle. (Tighten together) M8 x 16mm Flange bolt : 3pcs. Cylinder baffle Tightening torque : N m kgf cm ( ft lbs) M6 x 12mm Flange bolt : 1pce. Tightening torque : N m kgf cm ( ft lbs) Ignition coil Install the ignition coil into the ignition coil bracket and attach it to the engine. Ignition coil Ignition coil bracket tightening torque M6 x 14mm Flange bolt : 2pcs. Tightening torque : N m kgf cm ( ft lbs) Muffler Install the muffler. M8 x 80mm Flange bolt : 1pce. Tightening torque : N m kgf cm ( ft lbs) M6 Flange nut : 2pcs. Tightening torque : N m kgf cm ( ft lbs) Muffler 32

36 5-4-4 Recoil starter Attach the recoil starter to the crankcase. M6 x 18mm Flange bolt : 3pcs. Tightening torque : N m kgf cm ( ft lbs) Recoil starter Rotor and Flywheel Install the Rotor and Flywheel. M8 x 195mm Rotor bolt : 1pce. Tightening torque : N m kgf cm ( ft lbs) NOTE 1: Wipe off any oil from the tapered shaft and hole before assembling. NOTE 2: Counterclockwise threads are applied onto the Rotor (through) bolt. Take cake when tightening Rotor Bolt Rotor Flywheel Air gap adjustment of flywheel and Ignition coil Adjust the air gap between flywheel and Ignition coil to 0.5mm with a feeler gauge. Attach the Ignition coil to the engine. Ignition coil Flywheel Air gap : 0.5 mm 33

37 5-4-7 Ignition coil and harness Tighten the bolt in place, making adjustments according to M6 x 4mm Flange bolt : 2pcs. Tightening torque : N m kgf cm ( ft lbs) Ignition coil harness Grommet Recoil guide Place the Ignition coil harness along the groove of the grommet and recoil guide to make it easier to assemble the blower housing. Caution : Do not forget to put the 2 pieces of pipe knock Blower housing Install the blower housing M8 x 55mm Flange bolt : 1pce. M8 x 90mm Flange bolt : 3pcs. Blower housing Tightening torque : N m kgf cm ( ft lbs) NOTE: Insert the grommet (Ignition coil harness) and recoil guide into the blower housing securely. 34

38 5-4-9 Rear cover, stator Install the rear cover of the generator and stator into the blower housing. Rear cover Stator Install the rear cover to the blower housing. M6 x 25mm Flange bolt : 3pcs. Rear cover Tightening torque : N m kgf cm ( ft lbs) NOTE: Make sure of the direction of rear cover during installation. Tighten Stator bolts (M5 : 2 pcs.) to the specified tightening torque, after installing Rear cover onto Blower housing. Stator bolt (M5 : 2pcs.) Tightening torque : N m kgf cm ( ft lbs) Rear cover, stator Install the Brush holder. Brush holder M5 x 14mm Screw 1pce. 35

39 Base Install the Base into the engine main body. M8 x 20 Bolt and washer : 4pcs. Tightening torque : N m kgf cm ( ft lbs) M6 Flange nut : 4pcs. Tightening torque : N m kgf cm ( ft lbs) Base NOTE: Avoid cutting your hand by the sharp edge of the base Front frame Install the front frame (L) and (R) onto the Base. Front frame Air cleaner bottom plate and carburetor Install the insulator,gaskets, carburetor, baffle stay, and air cleaner base plate into the cylinder head. Carburetor M6 Flange nut : 2pcs. Tightening torque : N m kgf cm ( ft lbs) NOTE: Please do not forget to install the gasket Air cleaner Install the element and air cleaner cover onto the air cleaner base plate. Air cleaner base plate Air cleaner M6 x 18mm Flange bolt : 1pce. 36

40 Fuel pipe Connect the fuel pipes from the fuel pump to the crankcase and carburetor and fasten with a hose clamp. Fuel pipe (Carburetor side) NOTE: Assemble with care. Avoid mis-connection of fuel pipes. Fuel pipe (Crank case side) Grounding wire Fasten the ground wire. Tightening torque : N m kgf cm ( ft lbs) Grounding wire Installing coupler Connect the harness of the control panel. Be sure to securely fasten the couplers of the harness before installing the control panel. Couplers NOTE: When fastening, make sure there are no mis-wiring of harness, or forgotten wiring. Couplers (Diode) Couplers (AVR) 37

41 Fuel tank Attach the fuel tank and the fuel cock. After the fuel tank is installed, connect the fuel line between fuel cock and fuel pump. Fuel tank Fuel cock bracket Install the fuel cock bracket into the base. (Install the rubber pipe with the hose clamp while the fuel cock is closed.) M6 x 12mm Flange bolt : 1pce. M6 Nut : 1pce. Fuel cock bracket Mounting angle Tightening torque : N m kgf cm ( ft lbs) Base surface Rear frame Attach the rear frame (L) and (R) to the Base. Front frame Rear frame 38

42 Case body, control panel Attach the case body (left and right). Install the bottom part of the case body and the mount together. M6 x 18mm Flange bolt : 4pcs. Case body Tightening torque : N m kgf cm ( ft lbs) NOTE: Install the bottom part of the case body correctly. Attach the upper part of the case body. M6 x 25 Screw and Washer : 2pcs. M6 x 20 Screw and Washer : 1pce. M4 x 110 Screw : 1pce. Tightening torque : N m kgf cm ( ft lbs) NOTE: Avoid gaps in the upper part of the case body when installing. Install the control panel into the case body. M4 x 14mm Screw 4pcs. M5 x 8mm Screw 4pcs. Tightening torque : N m kgf cm ( ft lbs) Case body Mount Control panel Recoil starter and guide Install the guide of the starter hundle. Install the guide and starter hundle after they are pushed through the mounting hole from inside of the case body. M4 x 10mm Tapping screw : 1pcs. Insert the overflow pipe through the hole in the bottom of the case body. Recoil starter hundle Guide Overflow pipe 39

43 Choke wire and rolling wire Set adjusting screw onto Choke wire bracket and fix nut. Fit choke wire with screw at choke lever swivel. NOTE: Make sure the carburetor chock is closed when turning the engine switch into CHOKE position. Also make sure the choke is fully opened when turning the engine switch into RUN position. Install the rolling wire into the wire plate and fuel cock behind the control panel. Wire Nut Choke wire Adjusting screw Choke wire Choke wire bracket Rolling wire Rear cover Attach the rear cover to the case body. M6 x 30 Screw and Washer : 4pcs. Tightening torque : N m kgf cm ( ft lbs) Rear cover Side panels (left and right) Attach the side panel (left and right) to the case body. M6 x 16.5mm Bolt : 2pcs. Side Panel This is the end of assembly procedures. 40

44 5-5) RECOIL STARTER Tools used : Long-nose pliers, retaining-ring pliers, protective goggles Caution : Please wear protective goggles before starting disassembly 1) Disassembly procedures (1) Unhook the spring. -1 Hold the starter handle, and pull out the starter rope. -2 Pull out all of the rope, and align the rope guide and the knot of the rope inside the reel. -3 Be sure to hold the reel with both thumbs so your fingers do not become be entangled. Starter rope -4 Pull the knot of the rope out from the reel, loosen the knot, then pull it up from the starter handle side (this should be done by two people). -5 Slowly rewind the rope until the reel stops while controlling the reel with both thumbs. Starter handle Caution : The pull of the spring is maximized while the rope is fully pulled out. Please do not release it suddenly, or relax your grip. 41

45 (2) Remove the small parts. -1 Hold the case, and remove the retaining-ring C with the ring pliers. -2 Beginning at the top, remove the retaining-ring, friction plate, and ratchet. Retaining-ring pliers Retaining-ring C (3) Remove the reel. -1 Move the reel to left and right at a 1/4 turns several times until it moves smoothly, gently holding it down. -2 Slowly lift the reel, removing it from the case. -3 Repeat (3) 1 and (3) 2 if the spring assembled in the reel sticks out. Retaining-ring C Friction spring Ratchet Friction plate Ratchet guide Return spring Caution : The reel is disassembled with the spring still assembled, so place it on a flat table without dropping, or shaking. Retaining-ring E Reel Spiral spring Case Disassembly is completed. 42

46 Caution: Please wear protective goggles before starting assembly. 2) Assembly procedure (1) Assemble the reel into the case. -1 Install the ratchet, and fasten it with retaining ring E. -2 Install the spiral spring in the reel. -3 Apply grease to the case. -4 Properly orient the inner end of the spring installed in the reel. -5 Hold the reel so that the shaft and hook part can be caught on the inner end of the spring, and softly drop into the case from the top. -6 Move the reel gently in the counter-clockwise direction, making sure that the spring catches. Ratchet Retaining-ring E Grease Reel Spiral spring Case (2) Install the small parts. -1 Install the ratchet guide and return spring into the reel. Ratchet guide Return spring (3) Installing friction plate, retaining ring C -1 Install by putting the friction spring end into the spring part of the ratchet guide. Align the cut of the friction plate to the cut of the recoil starter main body, and fasten with the retaining ring C. Be sure that the retaining ring is fitted into the grooves. Friction plate Retaining ring C Friction spring 43

47 (4) Inserting the rope. (this should be done by two people) -1 Thread the rope through the reel where the rope hole on the reel and rope guide are aligned. About 20cm -2 Thread the rope end through the rope guide and the rope hole of the reel, and pull 20cm out from the reel. -3 Tight the end of the rope. About 10mm (5) Keep pressure on the spring -1 Feed the rope.(the length of one rotation of the reel) from the attached hole of the reel and pull it out from teh hole of the case. On the reel side, let the rope that was pulled out hang over the notch of the reel. Fixed hole Rope Cut of the reel Pull off hole 44

48 -2 Wind the rope clockwise seven times with the rope hanging from the reel. Gently wind the rope onto the reel while removing any kinks in the rope from the knob side. Rope Assembly is completed. Cut of the reel Wind up for seven times clockwise These are the disassembly and assembly procedures, please be sure to review the following item checklist to insure that the parts securely installed. 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times. -1 When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction. -2 When the ratchet does not operate, please re-check if there are any missing parts such as the spring. (2) Pull the starter handle and try to pull the starter rope out to the limit. -1 When the starter rope remains in the rope groove of the reel, pressure is put on the spring. Pull out 30cm of the starter rope, holding the reel firmly with your thumb, and then pull the starter rope out towards of the recoil starter. Next, rewind it 1~2 times, controlling reel rotation. -2 When the starter rope does not return smoothly, or the starter handle is hangs down loosely, please add grease or mobile oil in the rotating and friction parts. If it still does not work, rewind 1~2 times. (In that case, confirm that the spring is not under pressure by following the previous procedure.) -3 Please re-assemble from the beginning if there was the sound when the spring was removed and the starter rope does not re-winded into the reel. 45

49 4) When... (1)The spring pops out -1 Hook the end hook of the spring to the notched part of the reel, and attach the spring, applying pressure with your fingers so that it isn t released from the groove. (Please wear gloves) -2 Hook the inside hook of the spring to the claw of the starter case while turning. Spiral spring Reel Please refer to assembly procedures. (2) Oil refill At the end of the season or when disassembling, add grease (preferably one that is heat resistant, if possible) or mobile oil to rotation parts, friction parts, and the spring. 46

50 6.TROUBLESHOOTING Check if engine speed is normal. 50Hz : 3,000rpm 60Hz : 3,600rpm NG Refer to "Engine dose not start (Start failure )" OK Check if brush is weared. Check if the total length of brush is 5mm or over. NG Check and replace brush. OK Check if stator coil is normal. Main coil Exciter coil NG Replace OK Check if rotor coil is normal. NG Replace OK Check if AVR is normal. NG Replace OK Check if wiring is break or improper connection. NG Replace when wiring is break or damage. Connect properly. 47

51 No DC current Check if DC coil of stator is normal. NG Replace OK Check if diode rectifier is normal. NG Replace OK Check if DC circuit breaker is normal. NG Replace OK Check if wiring is break or improper connection. NG Replace when wiring is break or damage. Connect properly. 48

52 Engine does not start (Start failure) Check the gasoline in the tank None Add gasoline Yes Oil warning lamp turns on when the recoil is pulled warning lamp is on Check the oil volume None Add oil (up to the rated volume) Yes Fuel cock is in the ON position Yes Gasoline leaks when the carburetor drain is loosened Yes NO NO Open the cock Clean, change the filter Confirm of the oil SW E/g GND Tester Resistance value 0 Change Oil SW Check for gasoline corrosion Corrosion Change gasoline Change the Oil sensor unit OK Remove the spark plug and check the electrode Attach the plug to the plug cap, and check for sparks by grounding the electrode Sparks Check the valve clearance of the compressed pressure (compression) Dry No spark NG Blockage of the fuel tube carburetor, such as noise, etc. Check for dirty plugs, or gap Check the connection (coupler, high tension cord) Adjustment 49

53 7. WIRING DIAGRAM 50Hz-230V GENERATOR Diode Rectifier CONTROL PANEL DC coil DC circuit breaker Gry Org - DC output terminal + Grn/Y AC circuit breaker R Brush (-) Brush (+) Field coil Org Org/Grn AVR Main coil Exciter coil LAMP "OIL" LAMP "RUN" INDICATOR UN Blk Blk W W AC receptacle Grn/Y Grn/Y Grn/Y ENGINE W Oil sensor control unit R W Engine switch Grn/Y Ignition coil Oil sensor Spark plug Brn Earth (ground) terminal Wiring color cord Blk : Black Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green/White Org : Orange Gry : Gray R : Red W : White Y : Yellow W/Blk : White/Black Grn/Y : Green/Yellow Pur : Purple Org/Grn : Orange/Green 50

54 50Hz-240V GENERATOR Diode Rectifier CONTROL PANEL DC coil DC circuit breaker Gry Org - DC output terminal + Grn/Y AC circuit breaker R Brush (-) Brush (+) Field coil Org Org/Grn AVR Main coil Exciter coil LAMP "OIL" LAMP "RUN" INDICATOR UN Blk Blk W W AC receptacle Grn/Y Grn/Y Grn/Y ENGINE W Oil sensor control unit R W Engine switch Grn/Y Ignition coil Oil sensor Spark plug Brn Earth (ground) terminal Wiring color cord Blk : Black Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green/White Org : Orange Gry : Gray R : Red W : White Y : Yellow W/Blk : White/Black Grn/Y : Green/Yellow Pur : Purple Org/Grn : Orange/Green 51

55 60Hz-120V GENERATOR Diode Rectifier CONTROL PANEL DC coil DC circuit breaker Gry Org - DC output terminal + Grn/Y AC circuit breaker R Brush (-) Brush (+) Field coil Org Org/Grn AVR Main coil Exciter coil LAMP "OIL" LAMP "RUN" INDICATOR UN Blk Blk W W AC receptacle Grn/Y Grn/Y ENGINE W Oil sensor control unit R W Engine switch Grn/Y Grn/Y Ignition coil Oil sensor Spark plug Brn Earth (ground) terminal Wiring color cord Blk : Black Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green/White Org : Orange Gry : Gray R : Red W : White Y : Yellow W/Blk : White/Black Grn/Y : Green/Yellow Pur : Purple Org/Grn : Orange/Green 52

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